EP2316637B1 - Method for manufacturing an integrated fibre compound component - Google Patents

Abstract

The method involves producing removable cores (26-29) into core molds, and applying bar-preforms (30-32) formed with reinforcing carbon fibers on the cores for forming reinforcing elements and arranging the cores at a common structure (23). The cores are supplied with web-like semi-finished products for creating an external shell (33). The common structure is inserted into a closed molding tool and filtered with hardenable plastic material. A fiber composite part is hardened by utilizing pressure and/or temperature, and the cores are removed. An independent claim is also included for a core mold for executing a method for producing an integral fiber composite part.

Description

The invention relates to a method for producing an integral fiber composite component, in particular an aerodynamic active surface, with a plurality of stiffening elements enclosed by an outer skin.

In addition, a core mold not covered by the present invention for simultaneously and flexibly producing the cores needed for the process will be described.

In modern aircraft, the classic aluminum materials are increasingly displaced by the use of fiber composite components, which are formed for example with carbon fiber reinforced thermosetting or thermoplastic plastic materials. In many cases complex structural components such as landing flaps or entire vertical stabilizers are already being produced throughout with such fiber composite materials, in particular with CFRP materials such as carbon fiber-reinforced epoxy resins.
Such structural components are due to their spatial dimensions and / or the complex geometric shape, usually created in the so-called differential construction, in which the structural components of a plurality of prefabricated individual components are combined with a generally simpler geometry in a final assembly step.
As an example, in this context, a landing flap for an aircraft may be mentioned, in which a plurality of transverse ribs for supporting the skin shell is fastened to a plurality of longitudinal bars extending parallel to one another. The outer contour of the transverse ribs and the shape of the skin shell ultimately defines the surface geometry of the skin shells and thus defines the aerodynamic behavior of the landing flap. In addition, all components must be mountable stress-free in order to avoid the introduction of additional loads in the structure.
The disadvantage of the differential design is, inter alia, that the individual parts assembled in an additional assembly step to the finished component Need to become. Furthermore, overlaps or flanges, which always require an additional weight, are generally required for the joining process between the components.

Further disadvantages arise from the preferred application finding rivet connection of the items. Since fiber composite components have significantly smaller hole strength compared to metallic materials, any introduced rivet hole statically represents a disadvantage that must be compensated by higher material thicknesses in the bore area. In order to be able to use such riveted joints at all on fiber composite components, increased material thicknesses and enlarged flange areas, for example, have to be provided on shell structures, so that in the event of a failure of the riveted joint, a repair to create another riveted joint is possible at all. All of these restrictions mean that the composite component is not dimensioned with regard to a maximum expected mechanical load but rather on production boundary conditions or safety-related repair requirements, which has an unnecessary weight-increasing effect.

In principle, the individual parts can also be joined by gluing, whereby at least the problem of reduced bearing fatigue strength is eliminated. However, for the so-called "structural bonding" on highly stressed components on aircraft with regard to the required surface pretreatment, fatigue resistance and resistance to impact loads (so-called "impact resistance"), there are still significant problems that an application for safety reasons at least in the field of civil aviation, not yet allowed.

A viable alternative to the differential design is the integral construction, in which fiber composite components are manufactured in one piece with a complex geometry, so that the above-mentioned disadvantages by the connection of a plurality of individual parts to form a complex forest structure accounts.

A major problem in the production of such integral components, which may be, for example, complete flaps, airbrakes, ailerons, flapper, slats, engine mounts, winglets, wings, tail, oars, doors, lids, panels, holders, etc., represent the undercut structures necessary in many cases to create the necessary stiffeners within the closed outer skin.

The WO 03/103933 A1 describes a fiber reinforced composite component and method of making the same, wherein the fiber composite member has a front and a back side and a cell forming wall structure disposed between the front and back sides, the structure having fiber reinforced wall elements extending along the length or width of the component extend the front and the back and which are formed by the application of an assembly of cores disposed side by side, which are covered with fiber-reinforced fiber material, wherein the material is cured after impregnation with resin to form the wall elements and wherein the cores to the Forming chambers that are connected or partially connected to the wall elements serve.

The US 2002/0090874 A1 describes a method for producing an aerodynamic effective surface with internal stiffeners in the component transverse direction. After curing a plastic matrix, the cores are pulled out of the component.

The DE 10 2004 009 744 A1 describes a method for producing a final contour accurate, dimensionally stable, sealed mold core.

The EP 1 764 307 A describes a method for manufacturing in a monolithic nose strip of an aerodynamic active surface.

The EP 1 310 351 A describes a method for producing a windmill blade with an integral longitudinal reinforcement in the form of a spar which can be produced by means of a core which can be pulled in the longitudinal direction of the windmill blade.

The object of the invention is to provide a simple method for producing a complex, integral fiber composite component with a plurality of undercut stiffening elements, which is also flexible in terms of varying structural constraints for the fiber composite component and can be embedded in a largely automated, industrialized manufacturing process. In addition, a core shape that is not encompassed by the present invention will be described in terms of changing design requirements to produce the cores needed for the process.

1. a) Herstellen einer Vielzahl von entfernbaren Kernen in einer Kemform, wobei die Kerne im Wesentlichen eine innere Oberflächengeometrie des Faserverbundbauteils abbilden,
2. b) Auflegen von mit Verstärkungsfasern gebildeten Vorformlingen auf die Kerne zur Ausbildung der Versteifungselemente und Anordnen der Kerne zu einem Gesamtaufbau,
3. c) Belegen der Kerne mit einem bahnförmigen Halbzeug zur Schaffung der Außenhaut,
4. d) Einbringen des Gesamtaufbaus in ein geschlossenes Formwerkzeug und Infiltrieren des Gesamtaufbaus mit einem aushärtbaren Kunststoffmaterial,
5. e) Aushärten zum fertigen Faserverbundbauteil durch die Anwendung von Druck und/oder Temperatur, und
6. f) Entfernen der Kerne.

This object is first achieved by a method according to claim 1 with the following method steps:

1. a) producing a plurality of removable cores in a core mold, wherein the cores form substantially an inner surface geometry of the fiber composite component,
2. b) placing preforms formed with reinforcing fibers on the cores to form the stiffening elements and arranging the cores into an overall structure,
3. c) covering the cores with a sheet-like semi-finished product to create the outer skin,
4. d) introducing the entire structure into a closed mold and infiltrating the overall structure with a curable plastic material,
5. e) curing to the finished fiber composite component by the application of pressure and / or temperature, and
6. f) removing the cores.

In a first process step a), all cores required for carrying out the process are produced. For casting the cores serves a separate, closed core mold having at least one upper and one lower mold part. In the core form, a plurality of dividing plates, at least partially crossing each other to create cells, are arranged. In order to allow the arrangement of the separating plates with the creation of intersection regions, the dividing plates have, in each case transversely to their longitudinal course, longitudinal slots which extend approximately to the middle of the plate. Thus, the dividers can be mutually interlocked. In the crossing area, the longitudinal slots in the intersecting plates are opposite each other brought in. Each cell formed in this way in the core form represents a closed casting space for a core to be produced and can be filled with the core material via at least one bore in the lower and / or upper molding. If necessary, ventilation holes should also be provided in order to convey a fast and above all bubble-free casting of the cores.

The two mold parts of the core mold define an image of an "inner" surface geometry of the fiber composite component to be produced, which may be, for example, a landing flap. In the case of the production of a landing flap, the dividing plates between the cells are designed, for example, as spar sheets and as ribbed sheets. The spar sheets and the ribbed sheets represent a placeholder for the optionally subsequently undercut stiffening elements in the form of (longitudinal) spars and (transverse) ribs which arise later in the fiber composite component.

For the production of the cores, the spar sheets and the rib sheets are preferably inserted into the lower mold part, which is provided with grooves for this purpose, and the entire assembly is closed by placing the upper mold part. Subsequently, the core material is introduced through the holes in the moldings in the closed core mold and cured.

As the core material, a low-melting substance, for example, a wax, a metal alloy or the like can be used. Alternatively, an initially solidifying substance can be used for the core material, which is subsequently completely dissolved by a suitable solvent, such as water, dilution or the like, and rinsed out of the core mold in the last process step. Irrespective of the core material used, it should have a sufficient compressive strength of at least 8 bar for the subsequent infiltration process ("RTM process"). The removal of the cores is carried out by means of subsequently introduced into the outer skin holes through which the solvent is introduced to dissolve the cores and the core material can flow. Technical epoxy resin systems for the aircraft industry today generally have such high curing temperatures (≈ 180 ° C) that the use of fusible cores is not indicated. The matrix-type overall structure with all cores (so-called "cores" composite) forms the desired inner surface geometry of the later fiber composite component to be produced. Design changes to the fiber composite component, such as changes in the thickness of the spars and / or ribs, can be easily and quickly implemented by the exchange of the respective dividers without the need for costly modifications to the (RTM) mold used for the final infiltration process. For this purpose, the core mold is preferably formed with an easily workable material, such as an aluminum alloy.

In a second process step b) preforms formed with reinforcing fibers (so-called dry "preforms" with binder) are placed on all sides on the cores, in particular to form the fiber reinforcements for the spars, the ribs and the outer skin. If necessary, several preforms can be placed one above the other. Subsequently, the cores are positioned to each other to image the desired shape of the fiber composite component. In the case of the production of a landing flap, the cores are first positioned in the direction of the longitudinal extension of the landing flap and then the cores are added in rows in the transverse direction. Since the preforms or the preforms are already provided with a binder, they have a certain dimensional stability.

In the third method step c), the mutually positioned and aligned cores are provided with a sheet-like, formed with reinforcing fibers semi-finished to create the preferably self-contained outer skin. The semifinished product is preferably a highly drapeable / elastic fabric, which, in the ideal case, adapts to the surface geometry predetermined by the cores, generally two-dimensionally curved, in a wrinkle-free manner. Both the fiber preforms and the web-shaped semifinished product are preferably formed with carbon fibers. In principle, all fibers suitable as reinforcing fibers, such as, for example, glass fibers, ceramic fibers, natural fibers (hemp), etc., can be used.

The fixation of the preforms and the web-shaped semifinished product can be done by subsequent "binding" with a thermoplastic material, for example, by spraying in powder form. Alternatively, a suitable thermoplastic binder may already be incorporated in the preforms or the band-shaped semifinished product, so that a simple heating to fix the position of the preforms or semifinished product on the cores is sufficient. To fill unwanted voids, especially between the cores occupied by the preforms, it is generally necessary to additionally insert gussets and / or individual reinforcing fiber strands ("rovings") or multiple layers of reinforcing fabric between the cores.

In the fourth method step d), the introduction of the overall structure thus created takes place in an at least two-part, preferably metallic, molding tool. its defined by the mold halves inner surface geometry with very high accuracy embodies the desired surface geometry of the fiber composite component to be produced. After closing the at least two mold halves of the overall structure in the known resin infiltration process ("RTM" method ≡ Resin Transfer Molding process) with a curable, optionally under pressure plastic material, in particular a thermosetting epoxy resin impregnated or impregnated. The metallic mold is an RTM mold made with high precision from a high strength and temperature resistant steel. The simultaneous application of a negative pressure to the RTM mold accelerates the infiltration process or the injection process and avoids the risk of the formation of air pockets and cavities. The heating of the RTM molding tool is direct and / or indirect. In the case of indirect heating, the entire RTM mold is placed in an oven while in direct heating, heaters are integrated directly into the mold. These heating devices can be formed with electrical heating elements or with bores through which a heatable liquid, in particular oil, is passed.

In the fifth method step e), the curing of the finished fiber composite component by the application of pressure and / or temperature and in the last, sixth step f) the cores are finally removed by heating and / or the introduction of a solvent from the fiber composite component. For this purpose, it is usually necessary to introduce small holes in the closed outer skin to allow the flow of dissolved core material or the liquefied core material. Alternatively, this can be used in the region of the corners arranged openings in the transverse ribs, which serve in the finished component for the outflow of water of condensation.

Thus, the use of a two-dimensional matrix arrangement of dissolvable (fusible) or subsequently removable cores allows the method according to the invention to easily produce integral fiber composite components having a complex inner undercut stiffening structure.

An advantageous development of the method provides that the cores are provided after casting and curing with an impermeable layer. This prevents uncontrolled plastic material from being pressed into the cores during the final infiltration process and, as a result, after the Hardening and dissolution of the cores, an undefined inner surface of the fiber composite component ("casting trees") is formed. This layer can at the same time have non-stick properties, in order to also enable the detachment or detachment of this layer from the finished component.

Furthermore, it is provided that the stiffening elements are designed in particular as integrally formed to the outer skin ribs and spars. Basically, however, the method is not limited to a classic spar-rib structure with outer skin, as it is traditionally used, for example, in the case of wings, horizontal stabilizers, vertical stabilizers and landing flaps of aircraft. Rather, with appropriate arrangement and shape of the partitions in the core form almost any internally stiffened hollow structures can be produced with a closed outer skin as a fiber composite component. Furthermore, it is not necessary that the partitions, which are designed in the case of a landing flap as spar plates and ribbed plates, cut in the crossing area at an angle of 90 °. Basically, any angle and deviating from the straight-line shape, for example, curved course of the separating plates within the core shape are possible. In addition to the dividing plates deviating from the wing cross-sectional geometry shown by way of example any height contour can be imparted to produce fiber composite components with a variable within wide limits two-fold and at the same time self-contained surface geometry.

The method is intended in particular for automated, industrial production of fiber composite components in larger numbers for passenger aviation, in which at present still predominantly manufactured in conventional individual part structure structural fiber composite components with spar-rib structures apply.

According to a further development of the method according to the invention it is provided that prior to placing the sheet-shaped semi-finished in at least one longitudinal recess, in particular a groove, in at least one core, a stringer preform is introduced, wherein a support is effected by at least one subsequently inserted support body.

This makes it possible, in addition to the stiffening elements, for example in the shape of spars and ribs, longitudinal reinforcing elements, for example in the form of hat stringers or Ω-stringers integrally to form the outer skin surrounding the fiber composite component. As a support body are preferred Inflatable plastic hoses (film hoses) are used, which remain in the finished composite component or, if necessary, can be pulled out laterally. Alternatively, serve as a support body dissolvable or fusible cores, which are also used for the other cores with undercuts.

Moreover, a core form not covered by the present invention will be described. Characterized in that the core mold has a multiplicity of cells which are enclosed between an upper and a lower mold part for defining the inner surface geometry of an outer skin, the cells being formed with a multiplicity of dividing plates running in each case at a distance from one another, in particular ribbed plates and spar sheets, which at least partially intersect, and each cell has at least one bore for feeding the core material,
a simultaneous production of all necessary for the implementation of the method cores is possible.
Moreover, the baffles and the at least two mold halves of the core mold are preferably made with an easily machinable metal alloy, for example with an aluminum alloy. Design changes to the fiber composite component can thus be implemented by the removal of part of sheet metal material and / or by an exchange of dividing plates. If, for example, the material thickness of a stiffening element in the finished fiber composite component is changed out of static considerations, it is sufficient to exchange the relevant separating plate with another separating plate with the required material thickness.

Further advantageous embodiments of the method and the core shape are set forth in the further claims.

Fig. 1

Eine isometrische Ansicht einer Kernform zur Herstellung der Kerne,

Fig. 2

eine Querschnittsdarstellung durch drei ausgerichtete Kerne mit Vorformlingen und Halbzeug,

Fig. 3

einen Querschnitt durch den Gesamtaufbau der vollständigen Verstärkungsfaseranordnung für eine Landeklappe,

Fig. 4

einen Ausschnitt aus der Fig. 3 in einem Anschlussbereich zwischen einem vorderen Holm-Vorformling und dem bahnförmigen Halbzeug mit dem für den RTM-Prozess benutzten Formwerkzeug,

Fig. 5

einen weiteren Ausschnitt aus der Fig. 3 im Bereich eines Stringer-Vorformlings,

Fig. 6

eine Schnittdarstellung entlang der Schnittlinie VI-VI in der Fig. 3 im Bereich eines integral zu einer (Quer-)Rippe ausgestalteten Lasteinleitungspunktes,

Fig. 7

eine Ausführungsvariante der Kernform mit Positioniermitteln für die Kerne,

Fig. 8

einen vergrößerten Ausschnitt aus der Fig. 7,

Fig. 9

eine schematische Darstellung des Aufbringens des bahnförmigen Halbzeugs für die Bildung der Außenhaut,

Fig. 10

eine Darstellung eines Zuschnittes sowie eines hieraus geformten Eck-Vorformlings,

Fig. 11

eine Darstellung eines Zuschnittes sowie eines hiermit gebildeten Rippen-Vorformlings, und

Fig. 12

eine isometrische Darstellung einer Landeklappe als ein Beispiel für ein integral verfahrensgemäß gefertigtes Faserverbundbauteil mit innenliegenden, hinterschnittenen Versteifungselementen.

In the drawing shows:

Fig. 1

An isometric view of a core mold for making the cores,

Fig. 2

a cross-sectional view through three aligned cores with preforms and semi-finished,

Fig. 3

a cross-section through the overall structure of the complete reinforcing fiber arrangement for a landing flap,

Fig. 4

a section of the Fig. 3 in a connection region between a front spar preform and the sheet-like semifinished product with the molding tool used for the RTM process,

Fig. 5

another section of the Fig. 3 in the area of a stringer preform,

Fig. 6

a sectional view along the section line VI-VI in the Fig. 3 in the region of a load introduction point designed integrally with a (transverse) rib,

Fig. 7

an embodiment variant of the core mold with positioning means for the cores,

Fig. 8

an enlarged section of the Fig. 7 .

Fig. 9

a schematic representation of the application of the web-shaped semifinished product for the formation of the outer skin,

Fig. 10

an illustration of a blank as well as a corner preform formed therefrom,

Fig. 11

a representation of a blank and a rib preform formed therewith, and

Fig. 12

an isometric view of a landing flap as an example of an integrally manufactured fiber composite component with internal, undercut stiffening elements.

In the drawing, the same constructive elements each have the same reference numerals. In the further course of the description, the method and the devices used for the implementation, in particular the core mold for the production of all cores, are shown side by side.

The Fig. 1 shows an isometric view of the mold used for the production of the cores for performing the method using the example of a landing flap for an aircraft.

A core mold 1 comprises a lower and an upper mold part 2, 3. In the mold, a plurality of not individually designated baffles are arranged, which are designed for the exemplary case of manufacturing a landing flap as Holmbleche and arranged transversely rib plates. Of the spar and the finned plates only a front Holmblech 4 and a front rib plate 5 are provided with a reference numeral. A cross-sectional geometry of the ribbed plate 5 follows the cross-sectional geometry of the landing flap in this area. The Holmbleche 4 are not provided with reference numerals slots in the lower and / or upper mold part 2.3 can be inserted and thereby guided. The ribbed plate 5 has in the embodiment shown a total of three slots, of which only one front slot is provided with the reference numeral 6, wherein the slots each extend from an upper edge of the ribbed plate 5 to about its central region. The Holmblech 4 also has three slots or elongated recesses, of which only the front slot 7 is provided with a reference numeral. In contrast to the slots 6 in the rib plates 5, the slots 7 extend in the Holmblechen 4 respectively starting from the bottom to approximately a central region of the respective spar plate 4. As a result of the slot arrangement described, the spar sheets 4 on the rib plates 5 to form unspecified crossing areas and a plurality of cells in the direction of the arrows (alternately) are plugged. A cell 8 is representative of the remainder, corresponding to constructed cells, provided with a reference numeral. The total of eight cells in the Fig. 1 On the underside, the molding 2 in the region of the cell 8, like the other cells also, has a small bore 9 through which a suitable, liquid core material can be introduced. Alternatively, the holes can also be provided in the upper mold part 3. Furthermore, additional vent holes 9a may be provided. Before filling the core material for the simultaneous production of all eight cores, the dividing plates are inserted or plugged together and the two mold parts 2, 3 are closed to create the core mold 1.

The core material of the undercut dissolvable cores is a fusible material whose melting point is above the curing temperature of the matrix material or a curable substance, the subsequent by a suitable solvent, such as water, chemical solvents or the like, can be redissolved and rinsed out of the later component. The solution process can be physical or chemical. When using epoxy resins, it is generally preferable to use soluble cores because of the generally high curing temperature of up to 200 ° C., since the temperatures required to melt the cores can damage the epoxy resin matrix. However, melt-dissolvable cores can be advantageously used with thermosets that are cured at lower temperatures. To remove the cores are subsequently introduced holes in the outer skin and / or arranged respectively in corner regions of the transverse ribs openings, which later serve as drainage openings for condensation water. Depending on the core material used, it may be necessary to additionally provide the cores with a release film or a release layer, ie to impregnate them against the penetration of the plastic material used for the production of the finished fiber composite component in the resin infiltration process, in particular an epoxy resin system.

The lower mold part 2 further has three longitudinal webs with a slightly trapezoidal cross-sectional geometry, of which the central web carries the reference numeral 10. The webs 10 extending parallel to the wooden sheets 4 effect in the cores the underside formation of longitudinal depressions, in particular of trapezoidal grooves, which serve for the later production of longitudinal reinforcing elements, in particular in the form of hat stringers.

The core mold 1 including the partition plates is preferably formed with a readily workable material such as an aluminum alloy or the like. As a result, structural changes to the later fiber composite component, for example in the form of an increased or reduced material thickness of the spars, can be rapidly realized by the replacement of the respective spar plate or by the removal of material of the affected spar plate. In particular, it is no longer necessary to change the structurally very complex and difficult-to-machine shape for the later resin infiltration process (RTM process) using high-strength steel molds, since only the outer mold is formed with a high-strength steel (high-temperature chromium nickel alloy) whose geometry is fixed early. With the simultaneous production of all required cores in the described device, the first process step a) is completed.

The Fig. 2 FIG. 4 illustrates very schematically a cross section through an upper portion of a core having a plurality of preforms and two layers of a sheet-like semifinished product, which represent a section of an overall structure of a reinforcing fiber arrangement for the subsequent fiber composite component.

In the course of the second process step b), a multiplicity of different preforms are placed on the cores. Subsequently, the cores are grouped into an overall structure, which essentially reflects an inner surface geometry of the fiber composite component to be produced (cf. Fig. 1 ).

At a middle core 11 close on both sides of the cores 12,13. Using the example of this central core 11, the layer structure will be explained by way of example. On the core 11, a prefabricated corner preform 14 (so-called "preform") is first placed.

A preform, such as the corner preform 14, is a flat blank with any outer contour of a multiaxial fiber web (so-called "NCF" Non Crimped Fibers) or fabric, in particular carbon fiber formed, sheet-like semifinished product, where appropriate, to create a three-dimensional Structure was partially folded and / or draped at least once. In principle, a preform can be given any geometrically possible shape by folding, draping and cutting. Ultimately, each preform is produced with a suitable, in particular a power flow-compatible or load-oriented course of the reinforcing fibers. The preforms are made, for example, with a fabric and / or a scrim ("multiaxial scrim") of reinforcing fibers in ± 45 ° and in 0 ° / 90 ° configuration.

This is followed by a skin preform 15. Subsequently, spar or rib preforms 16, 17 for creating the relevant stiffening elements are respectively applied to opposite side surfaces 18, 19 of the core 11 in the required number. Further, optional intermediate preforms 20 may be provided between the cores, as needed. It is crucial that the corner preforms 14 and the skin preforms 15 are each arranged overlapping one another in the region of edges 21, 22. The same applies to the arrangement of the spar preforms or rib preforms 16,17 on the underlying skin preforms 15. This interlocking or overlapping of the preforms with each other intimate mechanical cohesion of the preforms is achieved in the later fiber composite component.

In order to avoid unwanted thickening in the later composite component, the circumferential edges 21,22 of all cores on a plurality of flat, mutually stepped depressions (not labeled), whose depth corresponds exactly to the respective material thickness of the superimposed preforms. As a result, a close tolerance of the fiber volume fraction of, for example, 60% is achieved in an interval of ± 4% in the finished component. Corresponding to the number of overlapping layers, a corresponding number of stepped, staggered paragraphs is provided. The preforms have on at least one side at least in sections a tab (flange), which is folded along one of the edges 21,22 of the core 11, that is brought to bear against one of the side surfaces 18,19 of the core 11. In this case, the tabs lie in depressions of the core 11, in order to achieve an upwardly smooth conclusion. The depressions can be configured in several stages in the case where several tabs are to be placed one above the other (cf. Fig. 4 ). The tabs may alternatively be slotted to follow curved edges of the cores can. Preferably, the preforms have on all sides in each case continuously configured tabs.

Thereafter, the cores 11 to 13 are arranged in matrix form with respect to one another so that they correspond to an inner contour of the later fiber composite component, that is to say the cores 11 to 13 provided with the preforms are again arranged in such a way as to form an overall structure 23, as originally of the core form after the casting process were removed (see. Fig. 1 ). In the presentation of the Fig. 2 only the upper regions of the cores 11 to 13 are shown, in the region of the lower regions of the cores 11 to 13 is moved according to the above-described procedure in the arrangement of the preforms.

The preforms are preferably made with a scrim, with a fabric or with a plurality of discrete carbon fibers or carbon fiber rovings. To complete the overall structure 23, which later forms the reinforcing fiber arrangement of the composite component, gussets 24 are inserted into regions between the cores 12 to 13.

Finally, in a third method step c), the overall structure 23 of the cores is covered with at least one layer of a sheet-like semifinished product 25 in order to provide the subsequent reinforcement for the outer skin of the fiber composite component.

The sheet-like semifinished product 25 is preferably a highly drape-like fabric or fabric made of carbon fibers, which is generally the one Twofold curved surface geometry of cores 11 to 13 can follow wrinkle-free. The above-described sequence of applying the preforms or the web-shaped semifinished product 25 is used in all cores. Moreover, it may be necessary, for filling cavities, if appropriate, to insert individual carbon fiber gussets formed with carbon fiber rovings 24 into the overall structure 23. The semifinished product 25 rests on top of a hatched, unmarked upper part of an RTM molding tool.

For fixing the position of the preforms and the sheet-shaped semi-finished product 25 on the cores 11 to 13, it may also be advantageous to apply, for example, a thermoplastic binder. Alternatively, it is possible to use preforms or strip-shaped semi-finished products which are already equipped ("prebound") with a thermoplastic binder by the manufacturer, so that heating is sufficient for fixing the position.

The Fig. 3 shows a schematic cross section through the overall structure of the dry reinforcing fiber assembly, while the Fig. 4 a cutout enlargement in the area between the spar preforms and the outer skin forming sheet-like semifinished product represents. In addition, at the same time on the Fig. 3.4 Referenced.

The dry (reinforcing fiber) overall structure 23 includes inter alia four cores 26 to 29, which are separated by three spar preforms 30 to 32 and surrounded by a sheet-like semi-finished product 33 to form the subsequent outer skin. Furthermore, six correspondingly preformed Stringer preforms, of which only one Stringer preform 34 is provided with a reference numeral, are provided in the cores 27 to 29, for the integral formation of the longitudinal stiffening profiles, in particular the stringer or the Ω stringer or the hat -Stringer, serve in the later composite component.

This overall structure 23 is inserted in process step d) for the infiltration process or the RTM process in a closed mold 35. The mold 35 is formed with a high-strength and heat-resistant steel alloy. Only by the mold 35, the outer surface geometry of the composite component is defined. After complete infiltration of the overall structure 23 by means of a curable plastic material, in particular an epoxy resin system or the like, the complete curing to the finished fiber composite component takes place in method step e). The necessary heating The RTM tool can be powered by direct or indirect heating. The cores 26 to 29 are removed or dissolved in the last method step f) by melting or rinsing. Holes in each cell, which is bounded by two ribs and spars, are subsequently inserted into the outer skin and can later serve for drainage purposes, for carrying out material investigations and for maintenance and inspection tasks.

Reliable testing of the finished integral composite component for air inclusions, delaminations, foreign body inclusions, thickness variations etc. is possible if necessary.

The Fig. 4 shows a detailed layer structure in the terminal region of the front spar 26 to the outer skin 33 within the overall structure 23 of the reinforcing fiber assembly. Both cores 26, 27 are again covered with corner preforms 36, 37. On the corner preforms 36, 37, the skin preforms 38, 39 are overlapping. Then follow two spar preforms 40,41 separated by an intermediate preform 42. Between the cores 26,27 to achieve a sufficiently flat surface is still a (reinforcing fiber) gusset 43 with an approximately triangular cross-sectional geometry. The upper termination of the overall arrangement 23 is again formed by two layers of a sheet-like semi-finished product 44. As a result of the overlapping layering in the edge region of the preforms, a very intimate bond and thus high strength of the resulting fiber composite component is achieved.

The Fig. 5 represents another section of the Fig. 3 and illustrates in a detailed view the arrangement of Stringer preforms for forming the longitudinal reinforcement, in particular in the form of an Ω-stringer or a hat-stringer.

The hat stringer 34 is in the embodiment of Fig. 5 formed with two nested stringer preforms 45,46 each having a trapezoidal cross-sectional geometry. The outer stringer preform 45 has two tabs 47, 48 arranged on both sides, which rest on the core 27 in step-like depressions 49, 50 in order to achieve a flat upper termination. The tabs 47,48 are away from each other, directed outward. The inner stringer preform 46 has two tabs 51,52 facing each other. The two Stringer preforms 45,46 are in a longitudinal recess 53 of the core 27, the is formed in the embodiment shown as a groove with a trapezoidal cross-sectional geometry, inserted. To support the stringer preforms 45, 46 in the final infiltration process, a hollow support body 54 is used, which may be formed, for example, with a conditionally elastic, inflatable film tube and which is pulled out of the longitudinal reinforcement profile 34 after the infiltration and curing process. The structure is closed at the top by two layers of the web-shaped semifinished product 44 (fabric). The support body may alternatively be formed with the same dissolvable (fusible or soluble) material as the cores 11-13.

The Fig. 6 shows a sectional view along the section line VI-VI in the Fig. 3 which illustrates the integration of a load introduction point into the later composite component in accordance with the method.

A load application point 55 is in the region between the core 27 and an adjacent core 56, which in the illustration of Fig. 3 with respect to the plane of the drawing behind the core 27, is designed as an integral part of a (transverse) rib 57 formed with at least one dry preform.

The core 27 is covered with a corner preform 58, a skin preform 59 and three rib preforms 60. The arrangement of the preforms on the second core 56 is mirror-symmetrical to the arrangement of the preforms on the core 27. In contrast to the "normal" structure of the spars or ribs with dry preforms, in the case of the creation of the load introduction point 55 a total of five additional load introduction preforms 61 are provided, which are arranged between the rib preforms 60 and thus provide an optimal, large-area power transmission into the overall structure of the fiber composite component. At their lower, not designated ends, the load introduction preforms 61 have a recess 62, which serves to carry out a cylindrical core 63 or bolt for forming a connection eye in the later composite component. Alternatively, the lower ends of the load introduction preforms 61 may also simply be laid around the core 63. The core 63 may be formed with the same dissolvable core materials as the other cores 11 to 13. The core 63 is further accommodated in a two-part mold 64, which in turn is embedded in a correspondingly designed cavity 65 in the mold 35. The division of the mold 64 ensures the removability. To carry out the load introduction preforms 61 by the later outer skin is a recess 67 or implementation with an edge reinforcement, in particular a slot, introduced into both layers of the web-shaped semifinished product 66. Alternatively, the eye can also be done by subsequently drilling the load introduction preforms 61 after the infiltration and curing has taken place. In this case, the cylindrical core 63, the two-part mold 64 and the cavity 65 in the mold 35 are dispensable.

The Fig. 7 schematically illustrates an alternative embodiment of the core shape Fig. 1 In particular, to facilitate a precise alignment of the cores after their production.

A core mold 68 comprises inter alia three spar sheets 69 to 71 and three fin sheets 72 to 74 as placeholders (partitions) for the ribs and the spars in the later fiber composite component. In the cells bounded by spar sheets 69 to 71 and the fin sheets 72 to 74, a total of eight cores, of which a core 75 is provided with a reference numeral, are prepared by filling in the curable core material as described above. The other components of the core mold 68 are not shown for the sake of clarity (cf. Fig. 1 ).

In contrast to the embodiment of the core mold 1 in accordance with the Fig. 1 In the core mold 68, a plurality of positioning means, of which two positioning means are provided by the reference numerals 76, 77 for the others, are provided. The positioning 76,77 are simply poured in the casting process of the cores and are pulled out after hardening or setting of the cores out of these. The positioning means 76, 77 are preferably formed with Teflon-coated wires or tubes to facilitate withdrawal from the cores.

The positioning means 76,77 are guided by non-designated holes in the fin plates 72,73 and follow, while maintaining a small distance of a few millimeters approximately the respective upper and lower contour of the edges of the spar sheets 69 to 71. Due to the curvature of the edges of the spar sheets 69 to 71 and the rectilinear course of the positioning means 76,77, however, this distance may vary. The positioning means 76,77 can be provided by means not shown clamping means with a mechanical bias to achieve a defined course.

The function of the positioning means 76, 77 is as follows: After the cast cores have hardened in method step a), the positioning means 76, 77 are pulled out of the cores. Then all the cores with the preforms, as in the description of the Fig. 2 to Fig. 6 explained, occupied (step b). Subsequently, the cores are arranged side by side to form a row (initially in each case parallel to the spar preforms) and precisely aligned with each other by the re-threading of the positioning means and held together. Subsequently, additional cores are grouped in the rib direction to a complete row and formed more rows until the complete structure is reached. After all rows have been arranged and aligned, the uniform covering of all cores with the sheet-like semifinished product for the outer skin reinforcement and thus the creation of the overall structure of the complete reinforcing fiber arrangement required for the production of the integral fiber composite component takes place in method step c). In particular, the material thickness of the spar preforms, the rib preforms and a number of layers of the wrapped sheet semifinished product is to be dimensioned so that the overall structure as accurately as possible and distortion-free in process step d) in the at least two-part mold for the RTM process can be introduced. Optionally, optional layers of reinforcing fibers must be incorporated into the overall structure for tolerance compensation. The positioning means also prevents the cores from shifting within the RTM tool and achieves a high and reproducible dimensional accuracy of the fiber composite component. The last two steps e) and f) comprise only the curing of the fiber composite component after the RTM process and the subsequent removal of the cores from the hollow composite component.

In the Fig. 8 an intersection region 78 is shown between the core 75 and another three adjacent, unmarked cores. The spatial extent of the cores between the preforms is illustrated by a dot matrix. In the crossing region 78, two continuous spar preforms 79,80 and four rib preforms 83 to 86 are arranged. Between the continuous spar preforms 79,80 vertical, even layers (so-called "blades") may optionally be inserted in order to increase the material thickness of the spars. Of central importance for the achievable strength of the later integral fiber composite component are the one-piece spar preforms 79 and 80 extending over the entire length of the component. In contrast, the rib preforms 83 to 86 are subdivided, that is to say they only extend between two adjacent bars , Upper, not designated tabs of the preforms 79 to 86 are each folded in the direction of equally not designated edges of the cores. in the Region of the crossing region 78 are mounted on the positioning means 76,77 quarter-circle segment-shaped discs 87,88 through which arise in the later composite component the quarter-circle segment-shaped drainage openings. The discs 87, 88 are preferably made with the same dissolvable material as the cores. According to the embodiment of Fig. 8 Such discs are provided at all other crossing areas for the creation of drainage openings. The four rib preforms 83 to 86 have for this purpose cutouts whose shape corresponds approximately to the geometric shape of the discs 87,88. The introduction of holes in the outer skin of the later fiber composite component to create a drainage possibility can be omitted due to the quarter-circle segment-shaped drainage openings, which is advantageous in static and aerodynamic terms and beyond simplifies the production. However, condensation water within the structure can only flow along the spars, since no drainage openings are provided in the spars.

As an alternative to the discs 87, 88 arranged in the corner regions of the cells, the ribbed plates 72 to 74 (cf. Fig. 7 ) are provided with appropriately arranged, for example, quarter-circle segment-shaped recesses or depressions, which run during the casting of the cores with the core material and in the later composite component also form corresponding drainage holes, inter alia, the outflow of condensation water from the flap along the (longitudinal) spars to ensure.

The Fig. 9 schematically illustrates the process of step c), in which the web-shaped semi-finished product is placed on the positioned and provided with preforms cores.

A sheet-shaped semi-finished product 89, in particular a drapable carbon fiber fabric, is stored on two coils 90,91 of the device used for this purpose. As a result of the downward movement of the two coils 90, 91 in the direction of the arrows pointing downwards, the sheet-shaped semi-finished product 89 is uniformly drawn off from the coils 90, 91 and placed on a prepared assembly 92 and cut to size. Advantageously, each coil 90,91 is brought during the downward movement of the prepared structure 92 and tracked in the vertical direction to support a wrinkle-free laying process.

If necessary, the process can be repeated at least once to obtain a higher material thickness of the sheet-like semifinished product 89 on the prepared structure 92 and thus the subsequent outer skin. It can be more, not shown pinch rollers be provided to the semi-finished 89 firmly and especially wrinkle-free to the structure 92 and optionally at the same time to secure in its position achieved by the application of heat and / or the application of a binder. After the application of the sheet-like semifinished product 89 to the assembly 92 is completed, the assembly 92 now embodies a finished overall structure 93 of a complete reinforcement fiber assembly for the production of the fiber composite component.

The Fig. 10 and 11 illustrate schematically a possible construction of two prefabricated preforms for covering the cores, that is ultimately to create the inner stiffening structure. Both preforms have been formed by cutting and folding from a flat blank. The blank used may be formed, for example, with a multiaxial fiber fabric or with a drapeable carbon fiber fabric. In the Fig. 10 . 11 the dashed lines each represent fold lines, the lines drawn with high line width symbolize respectively cut lines and the dotted lines respectively represent the original outline of the blank or hidden edges in the isometric view. Cut-out areas are hatched for further clarification.

The left part of the Fig. 10 shows a schematic example of a blank, which is used to produce the corner preform 94 shown in the right part. The corner preforms 94 are used to reinforce the edges of the cells within the fiber composite component as well as for the mechanical connection between the outer skin and the spar or the rib preforms by creating overlaps. The corner preform 94 has four tabs 95-98 formed by incision along the high-line-drawn line (square sections of the blank) and then flipped about 90 °, which are inserted into the circumferential, stepped depressions at the edges of the cores (see esp. Fig. 3 ).

The left part of the Fig. 11 FIG. 12 shows an exemplary blank for a ribbed preform 99 from which the ribbed preform 99 is shaped by cutting along the high line drawn lines (substantially square corner portions with inside rounded corners) and flipping the tabs 100-103 as it does is necessary to produce the integral ribs in the later composite component. The circumferential contour is in the schematic representation of the Fig. 11 However, in the practical embodiment, the inner surface geometry of the outer skin of the fiber composite component is shown in simplified form.

By using the rib preform 99 after Fig. 11 In each case, approximately quarter-circle-segment-shaped drainage openings can be generated in the corner regions of a rib in the composite component, which serve, inter alia, for dewatering the composite component. These cut out corner regions of the rib preform 99 are kept free during the casting process of the cores by the discs with the same geometry (see in particular. Fig. 7,8 ).

The geometric shape of a spar preform (not shown in the drawing) corresponds - apart from the lack of central recess and a significantly greater longitudinal extent (in the horizontal direction) - the shape of the corner preform 94 in accordance with Fig. 10 ,

The Fig. 12 Finally, the finished integral fiber composite component with a plurality of internal and undercut stiffening elements in a view from below.

A fiber composite component 104 produced in accordance with the method, which is a landing flap 105 in the exemplary embodiment shown, has a multiplicity of internal, undercut and stiffening elements 107 formed integrally with an outer skin 106. The stiffening elements 107 are exemplarily designed as (longitudinal) spars 108 to 110, and (transverse) ribs 111 to 113 running at an angle of approximately 90 ° for this purpose. The crossbars "crossing" spars 108 to 110 and ribs 111 to 113 form an internal stiffening structure with eight substantially self-contained cells, of which one cell is representative of all the others with the reference numeral 114. In the outer skin 106 are in the region of a bottom 115, respectively approximately centrally with respect to the cells, introduced bores, of which a bore is provided with the reference numeral 116. The holes are used for drainage of the cells and beyond as inspection or maintenance openings. The holes are dispensable in the case of the quarter-circle segment-shaped recesses in the (cross) ribs, at least with regard to the drainage of penetrated water, nevertheless for inspection and maintenance tasks of advantage.

Furthermore, the fiber composite component 104 is provided in the region of the lower side 115 with a load introduction point 117 designed integrally with the rib 112, for example in the form of an eye 118.

Corner regions of the ribs 111 to 113 each have a multiplicity of four-circle-shaped openings, of which one opening or recess representatively bears the reference numeral 119 for all others. The openings are used to rinse out the cores after completion of the RTM process and in the finished fiber composite component 104 as drainage holes for the discharge of condensate produced within the component. Notwithstanding the quarter-circle shape, the recesses 119 may have any other conceivable geometric shape.

Preferably, the fiber composite component 104 is made with a carbon fiber reinforced epoxy resin. In the case of integral fiber composite parts in which lower structural strength and / or impact resistance ("impact" strength) requirements are imposed, other thermosets, such as polyester resins, phenolic resins, etc., may alternatively be used. By way of exception, it is also possible to use thermoplastics if their mechanical properties still appear to be adequate for the particular application in comparison with the thermosets.

The fiber composite component 104 or the country flap 105 produced by means of the method according to the invention has excellent strength values and low weight due to its fully integrated design. In addition, the component can be produced in a largely fully automated process on an industrial scale with a high dimensional stability and a good repeatability of the geometric dimensions and a significantly reduced assembly costs.

Only later to be added equipment components, such as sealing elements, metal bushings, etc. must still be installed manually. The lightning protection fabric and / or lightning protection cables which are always necessary in the case of fiber composite components for adequate lightning protection are created even before the RTM process is completed in the outer skin layers by the embedding of copper wire meshes, copper wires, metallically conductive perforated louvered foils or the like.

If the fiber composite component to be produced is, for example, a rudder unit, a tailplane or a complete wing of an aircraft, the necessary electrical, pneumatic and hydraulic systems must additionally be installed.

Hereinafter, preferred embodiments of a core mold will be explained.

Embodiment 1: Core shape, the core shape having a plurality of cells sandwiched between upper and lower mold parts for defining the inner surface geometry of an outer skin, the cells being formed with a plurality of spaced apart baffles at least partially intersect and have a plurality of holes for performing positioning, and each cell has at least one bore for feeding the core material.

Embodiment 2: Core mold according to Embodiment 1, wherein the positioning means are formed as non-stick coated wires.

Embodiment 3: Core shape according to embodiment 1 or 2, wherein the separating plates are designed as Holmbleche and ribbed plates.

Embodiment 4: A core mold according to any one of Embodiments 1 to 3, wherein the mold parts and the partition plates are formed with an easily workable metal alloy, in particular, an aluminum alloy.

Embodiment 5: A core mold according to any one of Embodiments 1 to 4, wherein the spar sheets and the rib sheets have slits to allow the fitting together of rib sheets and spar sheets.

LIST OF REFERENCE NUMBERS

1

core shape

2

lower molding

3

upper molding

4

Holm sheet

5

fin sheet

6

Slot (ribbed plate)

7

Slot (Holmblech)

8th

Cell (mold core)

9

Bore (feed core material or venting)

9a

vent hole

10

web

11

core

12

core

13

core

14

Eck preform

15

Skin preform

16

Holm preform (rib preform)

17

Holm preform (rib preform)

18

Side surface (core)

19

Side surface (core)

20

Intermediate preform

21

edge

22

edge

23

Overall construction (reinforcing fiber arrangement composite component)

24

gore

25

sheet-shaped semi-finished product (drape-capable fabric, outer skin)

26

core

27

core

28

core

29

core

30

Holm preform

31

Holm preform

32

Holm preform

33

sheet-shaped semi-finished product (outer skin)

34

Stringer preform (longitudinal stiffening profile)

35

mold

36

Eck preform

37

Eck preform

38

Skin preform

39

Skin preform

40

Holm preform

41

Holm preform

42

Intermediate preform

43

gore

44

sheet-shaped semi-finished product (outer skin)

45

Stringer preform (outer)

46

Stringer preform (inner)

47

flap

48

flap

49

Deepening (core)

50

Deepening (core)

51

flap

52

flap

53

Longitudinal recess (core)

54

support body

55

Load transfer point

56

Core (resolvable)

57

(Transverse) rib

58

Eck preform

59

Skin preform (connection corner preform ↔ outer skin)

60

Ribs preform

61

Load application preforms

62

Recess (load introduction preforms)

63

cylindrical core (eye)

64

two-part form

65

Cavity (mold)

66

sheet-shaped semi-finished product (outer skin)

67

Recess (sheet-shaped semi-finished product)

68

Core shape (variant)

69

Holm sheet

70

Holm sheet

71

Holm sheet

72

fin sheet

73

fin sheet

74

fin sheet

75

core

76

Positioning agent (Teflon-coated wire)

77

Positioning agent (Teflon-coated wire)

78

crossing area

79

Holm preform

80

Holm preform

83

Ribs preform

84

Ribs preform

85

Ribs preform

86

Ribs preform

87

disc

88

disc

89

sheet-shaped semi-finished products (outer skin layers)

90

Kitchen sink

91

Kitchen sink

92

Construction (cores with preforms)

93

Overall structure (cores with preforms and outer skin layers)

94

Eck preform

95

flap

96

flap

97

flap

98

flap

99

Ribs preform

100

flap

101

flap

102

flap

103

flap

104

Fiber composite part

105

flap

106

Outer skin (fiber composite component)

107

stiffeners

108

Holm

109

Holm

110

Holm

111

rib

112

rib

113

rib

114

cell

115

Underside (fiber composite component)

116

Drilling (drainage / drainage)

117

Load transfer point

118

eye

119

Recess (drainage opening)

Claims (11)

1. Method for producing an integral fibre composite component (104), in particular an aerodynamic effective surface, with a plurality of stiffening members (107) surrounded by an outer skin (106), comprising the steps of:

   a) producing a plurality of removable cores (11-13, 26-29, 56, 75) in a core mould (1, 68), wherein the cores (11-13, 26-29, 56, 75) substantially form an inner surface geometry of the fibre composite component (104) with spars (108-110) and ribs (111-113) formed integral with the outer skin (106);

   b) placing preforms made from reinforcing fibres onto the cores (11-13, 26-29, 56, 75) to form the stiffening members (107) and arranging the cores (11-13, 26-29, 56, 75) to form an overall structure (23, 93);

   c) covering the cores (11-13, 26-29, 56, 75) with a web-like semi-finished product (25, 33, 44, 66, 89) to create the outer skin (106);

   d) introducing the overall structure (23, 93) into a closed moulding tool (35) and infiltrating the overall structure (23, 93) with a curable synthetic material;

   e) curing to form the finished fibre composite component (104) by applying pressure and/or temperature; and

   f) removing the cores (11-13, 26-29, 56, 75).
2. Method as claimed in claim 1, characterised in that the cores (11-13, 26-29, 56, 75) are provided with an impermeable layer.
3. Method as claimed in claim 1 or 2, characterised in that the cores are produced by pouring a soluble and/or meltable core material into the core mould (1, 68) and curing it.
4. Method as claimed in any one of claims 1 to 3, characterised in that positioning means (76, 77), in particular wires coated with a non-stick material, are cast into the cores (11-13, 26-29, 56, 75) and then removed so that the cores (11-13, 26-29, 56, 75) can be aligned with respect to one another.
5. Method as claimed in any one of claims 1 to 4, characterised in that a stringer preform (34, 45, 46) is introduced into at least one longitudinal depression (53), in particular a groove, in at least one core (11-13, 26-29, 56, 75) before placement of the web-like semi-finished product (25, 33, 44, 66, 89), wherein support is effected by at least one support body (54) which is subsequently inserted.
6. Method as claimed in any one of claims 1 to 5, characterised in that at least one load-introducing preform (61) is introduced between two cores (11-13, 26-29, 56, 75) in order to create a connection for an integral load-introducing point (55, 117), in particular an eyelet (118), wherein the at least one load-introducing preform (61) is passed through an aperture (62) within the web-like semi-finished product (25, 33, 44, 66, 89) into the moulding tool (35).
7. Method as claimed in any one of claims 1 to 6, characterised in that corner preforms (14, 36, 37, 58, 94) are first placed onto the cores (11-13, 26-29, 56, 75) to reinforce the corners and then skin preforms (15, 38, 39, 59) are placed, then rib preforms (60, 83-86) and spar preforms (16, 17, 30-32, 40, 41, 79-82) are laid, subsequently gussets (24, 42) are inserted between respectively adjacent cores (11-13, 26-29, 56, 75) and finally the cores (11-13, 26-29, 56, 75) are wrapped with the web-like semi-finished product (25, 33, 44, 66, 89).
8. Method as claimed in any one of claims 1 to 7, characterised in that at least the rib preforms (60, 83-86) have apertures to form drainage openings.
9. Method as claimed in any one of claims 1 to 8, characterised in that the positioning means (76, 77), in particular non-stick-coated wires, are passed through the finished cores (11-13, 26-29, 56, 75) after placement of the preforms, in order to ensure precise alignment.
10. Method as claimed in any one of claims 1 to 9, characterised in that the preforms are fixed in position by means of a bonding agent and/or that the preforms are already provided with the bonding agent by the manufacturer.
11. Method as claimed in any one of claims 1 to 10, characterised in that the preforms and the web-like semi-finished product are formed with reinforcing fibres, in particular carbon fibres.

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